Vehicular camera and lens assembly

• US 8,542,451 B2
• Filed: 03/25/2010
• Issued: 09/24/2013
• Est. Priority Date: 03/25/2009
• Status: Active Grant

• Current Assignee: Magna Electronics Incorporated (Magna International Incorporated)
• Original Assignee: Magna Electronics Incorporated (Magna International Incorporated)
• Inventors: Lu, Yuesheng, Byrne, Steven V., Sesti, Matthew C., Gibson, Joel S., Devota, Robert A.
• Primary Examiner(s): Sugarman, Scott J
• Assistant Examiner(s): Choudhury, Mustak
• Application Number:
  US13/260,400
• Publication Number:
  US 20120019940A1
• Time in Patent Office: 1,279 Days
• Field of Search: 359/811, 359/819, 359/830, 359/805, 359/796, 359/786, 359/787, 385/88
• US Class Current: 359/819
• CPC Class Codes: B60R 11/04 Mounting of cameras operative during drive; Arrangement of controls thereof relative to the vehicle
• CPC Class Codes: G02B 13/001 Miniaturised objectives for electronic devices, e.g. portable telephones, webcams, PDAs, small digital cameras G02B23/243 takes precedence
• CPC Class Codes: G02B 27/0025 for optical correction, e.g. distorsion, aberration
• CPC Class Codes: G02B 27/62 Optical apparatus specially adapted for adjusting optical elements during the assembly of optical systems
• CPC Class Codes: G02B 7/003 Alignment of optical elements G02B7/001, G02B7/002 take precedence; for mirrors G02B7/1822
• CPC Class Codes: G02B 7/02 for lenses supports for magnifying lenses G02B25/002
• CPC Class Codes: G02B 7/025 using glue
• CPC Class Codes: G02B 7/04 with mechanism for focusing or varying magnification
• CPC Class Codes: H01L 27/14618 Containers
• CPC Class Codes: H01L 27/14625 Optical elements or arrangements associated with the device
• CPC Class Codes: H01L 2924/00 Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
• CPC Class Codes: H01L 2924/0002 Not covered by any one of groups H01L24/00, H01L24/00 and H01L2224/00
• CPC Class Codes: H04N 23/51 Housings
• CPC Class Codes: H04N 23/54 Mounting of pick-up tubes, electronic image sensors, deviation or focusing coils
• CPC Class Codes: H04N 23/55 Optical parts specially adapted for electronic image sensors; Mounting thereof
• CPC Class Codes: H04N 23/57 Mechanical or electrical details of cameras or camera modules specially adapted for being embedded in other devices
• CPC Class Codes: H04N 23/63 by using electronic viewfinders
• CPC Class Codes: Y10T 29/49002 Electrical device making

Abstract

Low cost constructions of vehicular cameras employ various means for aligning and mounting the camera lens with respect to the imager. Such means include adhesive mounting using a UV curable adhesive, wherein the lens may be focused prior to cure of the adhesive. Other means include directly attaching the lens to the imager by adhesive; integrating the lens barrel and camera lens holder; dropping the lens barrel onto the surface of the imager; focusing the lens utilizing PCB mounting and focusing Screws; and focusing the lens by the relative positioning of camera front and back housings. Costs can also be contained by utilizing matching the resolution of the lens in conformance to human contrast sensitivity function, and by replacing optical chromatic aberration with digital chromatic aberration.

Claims

1. A vehicular camera including:

a lens comprising optical components;

a lens barrel holding said optical components therein;

an imager including an image sensor;

a lens holder;

wherein the lens barrel is bonded to the lens holder by a cured adhesive;

wherein the adhesive is initially curable in an initial curing process that comprises exposure to UV light, and wherein the initially-cured adhesive is further curable to a further cured strength in a secondary curing process;

wherein the adhesive is initially cured via the initial curing process after the lens is brought into focus with the imager and is optically center-aligned therewith;

wherein the initially-cured adhesive, as cured via the initial curing process, is sufficiently strong to initially hold the lens barrel relative to the lens holder with the lens optically center-aligned with the imager;

wherein, after the initial curing process, the camera is moved to the secondary curing process;

wherein, when further cured via the secondary curing process, the further-cured adhesive is sufficiently strong to hold the lens barrel relative to the lens holder for use of the camera in a vehicle; and

wherein the adhesive comprises an epoxy-amine adhesive.

2. A vehicular camera as claimed in claim 1, wherein the secondary curing process includes introducing heat to the initially-cured adhesive.

3. A vehicular camera as claimed in claim 1, wherein the further-cured adhesive maintains at least a minimum strength of bond between the lens barrel and lens holder after being exposed to at least one operating condition for a period of time, wherein the at least one operating condition includes a temperature of approximately 85 degrees Celsius.

4. A vehicular camera as claimed in claim 3, wherein the at least one operating condition includes a humidity of approximately 85%.

5. A vehicular camera as claimed in claim 3, wherein the period of time is greater than 1000 hours.

6. A vehicular camera as claimed in claim 3, wherein the minimum strength of bond is approximately the same as the strength of the fully cured adhesive.

7. A vehicular camera including:

a lens including a lens barrel for holding optical components therein;

a lens holder, wherein the lens barrel is connected to the lens holder by adhesive model AD VE 43812; and

an imager including an image sensor positioned for receiving video input from the lens.

8. A vehicular camera comprising:

a first camera housing having an integrated barrel portion for holding optical components;

wherein said optical components are mounted in the barrel portion so as to form a lens;

a retainer cap mounted to the barrel portion for containing and vertically positioning the optical components in the barrel portion;

imaging circuitry including an image sensor positioned for receiving optical images from the lens; and

a second camera housing, connected to the first camera housing so as to encase the imaging circuitry;

wherein the first camera housing is bonded to the second camera housing by a cured adhesive, wherein the adhesive is initially curable in an initial curing process that comprises exposure to UV light, and wherein the initially-cured adhesive is further curable to a further cured strength in a secondary curing process;

wherein the adhesive is initially cured via the initial curing process after the lens is brought into focus with the image sensor and is optically center-aligned therewith;

wherein the initially-cured adhesive, as cured via the initial curing process, is sufficiently strong to initially hold the first camera housing relative to the second camera housing with the lens optically center-aligned with the image sensor;

wherein, after the initial curing process, the camera is moved to the secondary curing process;

wherein, when further cured via the secondary curing process, the further-cured adhesive is sufficiently strong to hold the first camera housing relative to the second camera housing for use of the camera in a vehicle;

wherein the adhesive comprises an epoxy-amine adhesive; and

wherein the camera is configured to transmit to at least one other vehicular device signals relating to the images received by the imaging circuitry.

9. A vehicular camera, comprising

a lens including a lens barrel holding optical components therein;

an imager for receiving images from the lens; and

a housing encasing the imager and a portion of the lens barrel;

wherein the lens barrel includes a feature for guiding and seating a periphery of the lens barrel onto the surface of the imager;

means for securing the lens barrel to the housing;

means for ensuring focus between the lens and imager;

wherein the lens barrel is bonded to the housing by a cured adhesive, wherein the adhesive is initially curable in an initial curing process that comprises exposure to UV light, and wherein the initially-cured adhesive is further curable to a further cured strength in a secondary curing process;

wherein the adhesive is initially cured via the initial curing process after the lens is brought into focus with the imager and is optically center-aligned therewith;

wherein the initially-cured adhesive, as cured via the initial curing process, is sufficiently strong to initially hold the lens barrel relative to the housing with the lens optically center-aligned with the imager;

wherein, after the initial curing process, the camera is moved to the secondary curing process;

wherein, when further cured via the secondary curing process, the further-cured adhesive is sufficiently strong to hold the lens barrel relative to the housing for use of the camera in a vehicle; and

wherein the adhesive comprises an epoxy-amine adhesive.

10. A vehicular camera according to claim 9, wherein the adhesive comprises a low-temperature cure epoxy-amine adhesive.

11. A vehicular camera according to claim 9, wherein the securing means includes adhesive connecting the lens barrel to a printed circuit board on which the imager is mounted.

12. A vehicular camera according to claim 9, wherein the securing means includes retaining pins connected to the lens barrel and to a printed circuit board on which the imager is mounted.

13. A vehicular camera, comprising

a lens including a lens barrel holding optical components therein;

an imager for receiving images from the lens;

a printed circuit board (PCB) for mounting the imager;

a lens holder for mounting the lens barrel, the lens holder including a feature for guiding the lens barrel transversely relative to the imager;

set screws for mounting the PCB to the lens holder; and

means in combination with the set screws to hold the axial position of the PCB and imager relative to the lens;

wherein the lens barrel is bonded to the lens holder by a cured adhesive, wherein the adhesive is initially curable in an initial curing process that comprises exposure to UV light, and wherein the initially-cured adhesive is further curable to a further cured strength in a secondary curing process;

wherein the adhesive is initially cured via the initial curing process after the lens is brought into focus with the imager and is optically center-aligned therewith;

wherein the initially-cured adhesive, as cured via the initial curing process, is sufficiently strong to initially hold the lens barrel relative to the lens holder with the lens optically center-aligned with the imager;

wherein, after the initial curing process, the camera is moved to the secondary curing process;

wherein, when further cured via the secondary curing process, the further-cured adhesive is sufficiently strong to hold the lens barrel relative to the lens holder for use of the camera in a vehicle; and

wherein the adhesive comprises an epoxy-amine adhesive.

15. A vehicular camera according to claim 13, wherein the adhesive also fixes the PCB to the second camera housing.

14. A vehicular camera, comprising

a first camera housing having an integrated barrel portion for holding optical components;

optical components mounted in the barrel portion so as to form a lens;

an imager for receiving images from the lens;

a printed circuit board (PCB) for mounting the imager; and

a second camera housing to which the PCB is mounted, the first and second camera housings in combination encasing the imager and PCB;

wherein the first camera housing is bonded to the second camera housing by a cured adhesive, wherein the adhesive is initially curable in an initial curing process that comprises exposure to UV light, and wherein the initially-cured adhesive is further curable to a further cured strength in a secondary curing process;

wherein the adhesive is initially cured via the initial curing process after the lens is brought into focus with the image sensor and is optically center-aligned therewith;

wherein the initially-cured adhesive, as cured via the initial curing process, is sufficiently strong to initially hold the first camera housing relative to the second camera housing with the lens optically center-aligned with the image sensor;

wherein, after the initial curing process, the camera is moved to the secondary curing process;

wherein, when further cured via the secondary curing process, the further-cured adhesive is sufficiently strong to hold the first camera housing relative to the second camera housing for use of the camera in a vehicle; and

wherein the adhesive comprises an epoxy-amine adhesive.

16. A vehicular camera, comprising:

a camera housing having an integrated barrel portion for holding optical components;

optical components mounted in the barrel portion so as to form a lens;

an imager for receiving images from the lens;

a printed circuit board (PCB) for mounting the imager; and

wherein the PCB is bonded to the camera housing by a cured adhesive, wherein the adhesive is initially curable in an initial curing process that comprises exposure to UV light, and wherein the initially-cured adhesive is further curable to a further cured strength in a secondary curing process;

wherein the adhesive is initially cured via the initial curing process after the lens is brought into focus with the imager and is optically center-aligned therewith;

wherein the initially-cured adhesive, as cured via the initial curing process, is sufficiently strong to initially hold the PCB relative to the camera housing with the lens optically center-aligned with the imager;

wherein, after the initial curing process, the camera is moved to the secondary curing process;

wherein, when further cured via the secondary curing process, the further-cured adhesive is sufficiently strong to hold the PCB relative to the camera housing for use of the camera in a vehicle; and

wherein the adhesive comprises an epoxy-amine adhesive.

17. A vehicular camera, comprising:

a lens including a lens barrel holding optical components therein;

an imager for receiving images from the lens; and

a printed circuit board (PCB) for mounting the imager;

wherein the lens barrel is directly bonded to the imager by a transparent adhesive fixing the lens barrel to at least one of the imager and the PCB, the adhesive being cured only after the position of lens barrel relative to the imager is set to bring the lens in focus and optically center-aligned with the imager;

wherein the adhesive is initially curable in an initial curing process that comprises exposure to UV light, and wherein the initially-cured adhesive is further curable to a further cured strength in a secondary curing process;

wherein the adhesive is initially cured via the initial curing process after the lens is brought into focus with the imager and is optically center-aligned therewith;

wherein the initially-cured adhesive, as cured via the initial curing process, is sufficiently strong to initially hold the lens barrel relative to the at least one of the imager and the PCB with the lens optically center-aligned with the imager;

wherein, after the initial curing process, the camera is moved to the secondary curing process;

wherein, when further cured via the secondary curing process, the further-cured adhesive is sufficiently strong to hold the lens barrel relative to the at least one of the imager and the PCB for use of the camera in a vehicle; and

wherein the adhesive comprises an epoxy-amine adhesive.

18. A vehicular camera system comprising:

a lens;

an imager receiving images provided by the lens;

a display receiving video from the imager;

wherein the lens resolution is selected to meet but not substantially exceed a resolution determined from the size of the display, a distance between an observer and the display, a selected point on a contrast sensitivity function, and the size of the imager sensing surface;

wherein the lens includes a lens barrel holding optical components therein;

a lens holder, wherein the lens barrel is bonded to the lens holder by a cured adhesive, wherein the adhesive is initially curable in an initial curing process that comprises exposure to UV light, and wherein the initially-cured adhesive is further curable to a further cured strength in a secondary curing process;

wherein the adhesive is initially cured via the initial curing process after the lens is brought into focus with the imager and is optically center-aligned therewith;

wherein the initially-cured adhesive, as cured via the initial curing process, is sufficiently strong to initially hold the lens barrel relative to the lens holder with the lens optically center-aligned with the imager;

wherein, after the initial curing process, the camera is moved to the secondary curing process;

wherein, when further cured via the secondary curing process, the further-cured adhesive is sufficiently strong to hold the lens barrel relative to the lens holder for use of the camera in a vehicle; and

wherein the adhesive comprises an epoxy-amine adhesive.

19. A vehicular camera system comprising:

a lens;

an imager receiving images provided by the lens;

a display receiving video from the imager;

wherein the lens omits achromatic lenses and employs digital chromatic correction based on a predetermined chromatic aberration measurement;

wherein the lens includes a lens barrel holding optical components therein;

a lens holder, wherein the lens barrel is bonded to the lens holder by a cured adhesive, wherein the adhesive is initially curable in an initial curing process that comprises exposure to UV light, and wherein the initially-cured adhesive is further curable to a further cured strength in a secondary curing process;

wherein the adhesive is initially cured via the initial curing process after the lens is brought into focus with the imager and is optically center-aligned therewith;

wherein the initially-cured adhesive, as cured via the initial curing process, is sufficiently strong to initially hold the lens barrel relative to the lens holder with the lens optically center-aligned with the imager;

wherein, after the initial curing process, the camera is moved to the secondary curing process;

wherein, when further cured via the secondary curing process, the further-cured adhesive is sufficiently strong to hold the lens barrel relative to the lens holder for use of the camera in a vehicle; and

wherein the adhesive comprises an epoxy-amine adhesive.